VESPA GTS Super 125 i.e. (2009) Service Manual

MANUALE STAZIONE DI SERVIZIO

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Vespa GTS Super 125 i.e. (2009)

MANUALE

STAZIONE DI

SERVIZIO

Vespa GTS Super 125 i.e. (2009)

The descriptions and illustrations given in this publication are not binding. While the basic specifications as described and illustrated in this manual remain unchanged, PIAGGIO-GILERA reserves the right, at

any time and without being required to update this publication beforehand, to make any changes to

components, parts or accessories, which it considers necessary to improve the product or which are

required for manufacturing or construction reasons.

Not all versions/models shown in this publication are available in all countries. The availability of each

model should be checked at the official Piaggio sales network.

in whole or in part is prohibited."

PIAGGIO & C. S.p.A. - After sales

V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)

MANUALE STAZIONE DI

SERVIZIO

Vespa GTS Super 125 i.e. (2009)

Questo manuale per stazioni di servizio è stato realizzato da Piaggio & C. Spa per essere utilizzato dalle officine dei concessionari e sub-agenzie Piaggio-Gilera. Si presuppone che chi utilizza questa pubblicazione per la manutenzione e la riparazione dei veicoli Piaggio, abbia una conoscenza base dei principi della meccanica e dei procedimenti inerenti la tecnica della riparazione dei veicoli. Le variazioni importanti nelle caratteristiche dei veicoli o nelle specifiche operazioni di riparazione verranno comunicate attraverso aggiornamenti di questo manuale. Non si può comunque realizzare un lavoro completamente soddisfacente se non si dispone degli impianti e delle attrezzature necessarie, ed è per questo che vi invitiamo a consultare le pagine di questo manuale riguardanti l'attrezzatura specifica e il catalogo degli attrezzi specifici.

N.B. Provides key information to make the procedure easier to understand and carry out.

CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.

WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.

Personal safety Failure to completely observe these instructions will result in serious risk of personal

injury.

Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle to prevent damaging the environment.

Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious damage to the vehicle and sometimes even the invalidity of the guarantee.

INDEX OF TOPICS

CHARACTERISTICS CHAR

TOOLING TOOL

MAINTENANCE MAIN

TROUBLESHOOTING TROUBL

ELECTRICAL SYSTEM ELE SYS

ENGINE FROM VEHICLE ENG VE

INJECTION INJEC

SUSPENSIONS SUSP

BRAKING SYSTEM BRAK SYS

COOLING SYSTEM COOL SYS

CHASSIS CHAS

PRE-DELIVERY PRE DE

TIME TIME

INDEX OF TOPICS

CHARACTERISTICS CHAR

This section describes the general specifications of the vehicle.

Rules

This section describes general safety rules for any maintenance operations performed on the vehicle.

Safety rules

- If work can only be done on the vehicle with the engine running, make sure that the premises are wellventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaust fumes are toxic.

- The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin. Sulphuric acid is highly corrosive; in the event of contact with your eyes or skin, rinse thoroughly with abundant water and seek immediate medical attention.

- The battery produces hydrogen, a gas that can be highly explosive. Do not smoke and avoid sparks or flames near the battery, especially when charging it.

- Fuel is highly flammable and it can be explosive given some conditions. Do not smoke in the working area, and avoid naked flames or sparks.

- Clean the brake pads in a well-ventilated area, directing the jet of compressed air in such a way that you do not breathe in the dust produced by the wear of the friction material. Even though the latter contains no asbestos, inhaling dust is harmful.

Maintenance rules

- Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-original or non-conforming spare parts may damage the vehicle.

- Use only the appropriate tools designed for this vehicle.

- Always use new gaskets, sealing rings and split pins upon refitting.

- After removal, clean the components using non-flammable or low flash-point solvents. Lubricate all the work surfaces, except tapered couplings, before refitting these parts.

- After refitting, make sure that all the components have been installed correctly and work properly.

- For removal, overhaul and refit operations use only tools with metric measures. Metric bolts, nuts and screws are not interchangeable with coupling members with English measurement. Using unsuitable coupling members and tools may damage the vehicle.

- When carrying out maintenance operations on the vehicle that involve the electrical system, make sure the electric connections have been made properly, particularly the ground and battery connections.

Vespa GTS Super 125 i.e. (2009) Characteristics

CHAR - 7

Vehicle identification

Chassis prefix: ZAPM45100000 ÷ 1001 Engine prefix: M451M ÷ 1001

Dimensions and mass

WEIGHTS AND DIMENSIONS

Specification

Desc./Quantity

Kerb weight 158 ± 5 kg

Maximum weight allowed 340 kg

Maximum height 1170 mm

Overall width 755 mm

Maximum length 1930 mm

Wheelbase 1370 mm

Characteristics Vespa GTS Super 125 i.e. (2009)

CHAR - 8

Engine

DATA

Specification Desc./Quantity

Type single-cylinder, four-stroke and four liquid-cooled valves

Engine capacity 124 cm³

Bore x stroke 57 x 48.6 mm

Max. power 11 kW at 9750 rpm

MAX. torque 12 Nm at 7500 rpm

Timing system single overhead camshaft, chain-driven, on the left-hand side,

three-arm rocking levers set up with threaded set screw Compression ratio 12 ± 0.5: 1 Engine idle speed 1,750 ± 50 rpm

Air filter sponge, impregnated with mixture (50% petrol and 50% oil)

Starting system electric starter motor with freewheel

Lubrication with lobe pump (inside the crankcase) chain-driven and double

filter: mesh and paper

Fuel system Electronic injection with electric fuel pump

valve clearance intake: 0.10 mm - exhaust: 0.15 mm

Minimum lubrication pressure (100° C) 0.8 bar

Lubrication pressure 3.5 to 4 bar

Cooling Forced liquid circulation cooling.

OIL PUMP

Specification

Desc./Quantity

Type Trochoidal

Distance between the rotors Admissible limit clearance: 0.12 mm

Axial rotor clearance Limit values admitted: 0.09 mm

Distance between the outer rotor and the pump body Admissible limit clearance: 0.20 mm

Levelness 0.1 mm

BY-PASS

Specification

Desc./Quantity

Type With piston

Plunger diameter Ø 13.9 - 0.039 -0.057 mm

By-pass check up: Standard length 54.2 mm

Calibration pressure 4.5 bar

OIL FILTER

Specification

Desc./Quantity

Type Paper with pressure relief and anti-drain back by-pass valves

OIL MINIMUM PRESSURE INDICATOR LIGHT SWITCH

Specification

Desc./Quantity

Calibration 0.3 - 0.6 bar

HEAD LUBRICATION CONTROL JET

Specification

Desc./Quantity

Diameter 1 ± 0.05 mm *

* Tightening torque 5÷7 N·m

COOLING SYSTEM

Specification

Desc./Quantity

Cooling system capacity ~ 2.100 ÷ 2.150 l

Recommended fluid AGIP PERMANENT SPEZIAL

Sealing pressure Cap calibrated at 0.9 bar

THERMOSTAT

Specification

Desc./Quantity

Type Wax-type, with deviator

Vespa GTS Super 125 i.e. (2009) Characteristics

CHAR - 9

Specification Desc./Quantity

Starts opening at 85±2°C

ELECTRIC VENTILATION

Specification Desc./Quantity

Electric ventilation starts at 102°C Electric ventilation stops at 96°C

RADIATOR

Specification Desc./Quantity

Type Made of aluminium in two sections

WATER PUMP

Specification Desc./Quantity

Type Centrifugal

Control Electric

Transmission

TRANSMISSION

Specification Desc./Quantity

Transmission Automatic expandable pulley variator with torque server, V-

belt, automatic clutch, gear reduction unit and transmission

compartment with forced air circulation cooling

Capacities

CAPACITY

Specification

Desc./Quantity

Fuel tank (including a ~ 2 l reserve) ~ 9.2 l

Cooling system fluid ~ 2.100 ÷ 2.150 l

Engine oil approx. 1300 cc

Rear hub 250 cc

Electrical system

ELECTRICAL COMPONENTS

Specification

Desc./Quantity

Ignition/advance Electronic, with inductive discharge and variable advance with

three-dimensional mapping

Spark plug NGK CR8EKB

Battery 12V-12Ah

Fuses 1 30A - 2 15A - 4 7.5A

Generator alternating current

Characteristics Vespa GTS Super 125 i.e. (2009)

CHAR - 10

CHECKING REMOTE CONTROLS «A» OPERATING AS CIRCUIT BREAKERS

1) Check that, given regular conditions, there is no continuity between terminals 30 and 87.

2) Apply 12V voltage to power terminals 85 and 86 of the remote control.

3) With the remote control powered, check that there is continuity between terminals 30 and 87.

4) If these conditions are not fulfilled, the remote control is damaged and must be replaced.

To check buttons and switches, check that, according to their position, the continuity of contacts is correct as indicated in the following charts.

TURN INDICATOR SWITCH

ENGINE STOP SWITCH

HORN BUTTON

Vespa GTS Super 125 i.e. (2009) Characteristics

CHAR - 11

LIGHT SWITCH

STARTER BUTTON

KEY SWITCH

FUEL INJECTOR

Type: 3 holes Conicity of the nozzle: 20° Resistance at terminals: 13.7 to 15.2 Ohm

Characteristics Vespa GTS Super 125 i.e. (2009)

CHAR - 12

FUEL PUMP UNIT

Mechanical type pressure regulator operating at a pressure of 2.5 BAR Pump winding resistance: ~ 1.5 Ohm Input current during regular functioning: 1.4 - 1.8 A

ENGINE SPEED SENSOR

Resistance between pins 13 and 15: 100 to 150 Ohm at approx. 20°

ENGINE TEMPERATURE SENSOR

0° = 5900 Ohm +10° = 3800 Ohm +20° = 2500 Ohm +30° = 1700 Ohm +80° = 300 Ohm

MINIMUM OIL PRESSURE SENSOR

Normally closed switch Activation threshold: 0.3 - 0.6 bar With the engine off: continuity between terminal and ground

HV COIL

- Resistance of the primary = 0.5 Ohm ± 8%

- Resistance between primary and ground = infinite

- Resistance between primary and HV output = 3.1 KOhm ± 9%

Vespa GTS Super 125 i.e. (2009) Characteristics

CHAR - 13

- Presence of battery voltage between pins 22 and 26 of the interface cable harness upon shifting to ON and for 2 sec.

STATOR

Power: 450 W Resistance between terminals: 0.2 to 1 Ohm terminal insulation from ground

Frame and suspensions

CHASSIS AND SUSPENSIONS

Specification

Desc./Quantity

Type Unitised body made of stamped plate

Front suspension Single arm suspension (cantilever wheel) fitted with a double-

acting hydraulic shock absorber with coaxial spring

Front shock absorber axial travel 86.5 mm

Rear suspension Engine with swinging fork articulated to frame by means of an

arm with 2 degrees of freedom Pair of double-acting hydraulic

shock absorbers and coaxial springs with preloading adjust-

ment in 4 positions.

Rear shock absorber axial travel 89.5 mm

Brakes

BRAKES

Specification

Desc./Quantity

Front Ø 220 disc brake and floating calliper with Ø 25 mm twin plung-

ers and hydraulic control (lever on the far right end of the

handlebar)

Rear Ø 220 disc brake and calliper with two Ø 30 mm counteracting

plungers and hydraulic control (lever on the far left end of the

handlebar)

Characteristics Vespa GTS Super 125 i.e. (2009)

CHAR - 14

Wheels and tyres

WHEELS AND TYRES

Specification Desc./Quantity

Front wheels - light alloy rims 3.00x12 Rear wheels - light alloy rims 3.00x12

Front tyres 120/70-12" Tubeless

Rear tyres 130/70-12" Tubeless

TYRE PRESSURE

Specification Desc./Quantity

Front tyre pressure (when cold) 1.8 bar Rear tyre pressure (when cold) 2 bar

Tyre pressure (when cold) with passenger 2.2 bar

N.B.

CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE. REGULATE PRESSURE ACCORDING TO THE WEIGHT OF BOTH RIDER AND ACCESSORIES

Tightening Torques

STEERING ASSEMBLY

Name

Torque in Nm

Upper steering ring nut 35 ÷ 40 Lower steering ring nut 12 ÷ 14

Handlebar fixing screw 45 ÷ 50 (The two screws must be tightened to the prescribed

torque after having done so with the rear wheel axle nut. Safety

locks: see «Pre-delivery Operations»)

Fixing screws for the handlebar control unit U-bolts 7 ÷ 10

FRAME ASSEMBLY

Name

Torque in Nm

Engine-swinging arm pin 64 ÷ 72

swinging arm bolt - body shell 76 ÷ 83

Engine and vehicle side swinging arm junction bolt 33 to 41

Bolt of the Silent block support plate 42 ÷ 52

Centre stand bolt 32 ÷ 40

Side stand fixing bolt 35 ÷ 40

FRONT SUSPENSION

Name

Torque in Nm

Screw fixing the shock absorber to the shock absorber - calliper

attachment plate

20 ÷ 27

Wheel axle nut 74 ÷ 88

Wheel screw 20 ÷ 25

Screw fixing rear mudguard to steering 5 ÷ 6.5

shock absorber upper clamp 20 to 30

FRONT BRAKE

Name

Torque in Nm

Brake fluid pump-hose fitting 20 ÷ 25

Brake fluid pipe-calliper fitting 19 ÷ 24

Screw fixing calliper to the shock absorber - calliper plate at-

tachment

24 ÷ 27

Disc tightening screw 6 (Apply LOCTITE 242 threadlock, medium strength)

Oil bleed screw 12 - 16

Pad fixing pin 19.6 ÷ 24.5

Brake pump reservoir screws 1.5 ÷ 2

Brake disc screws 8 to 10

Vespa GTS Super 125 i.e. (2009) Characteristics

CHAR - 15

REAR SUSPENSION

Name Torque in Nm

Retainer for left shock absorber to crankcase support plate 20 ÷ 25

Shock absorber lower fitting 40 ÷ 45 Shock absorber upper fitting 20 ÷ 25

Rear wheel axle 104 ÷ 126

Screw fixing wheel to hub 20 ÷ 25

Screws for muffler - shock absorber support arm on engine 20 ÷ 25 (The two screws must be tightened to the prescribed

torque after having done so with the rear wheel axle nut. Safety

locks: see «Pre-delivery Operations»)

Engine- and vehicle-side swinging arm junction bolt 40 ÷ 45

REAR BRAKE

Name Torque in Nm

Brake fluid pump-hose fitting 20 ÷ 25

Brake fluid pipe-calliper fitting 20 to 25

Rear disc tightening bolt 11 ÷ 13

Oil bleed screw 12÷16

Calliper to engine tightening screw 20 ÷ 25

Brake pump reservoir screws 1.5 ÷ 2

Calliper coupling screw 30 ÷ 33

MUFFLER

Name Torque in Nm

Muffler heat guard fixing screw 4 ÷ 5

Screw for fixing muffler to mounting arm 20 ÷ 25

Lambda probe tightening on exhaust manifold 40 to 50

Exhaust manifold-muffler joint tightening 12÷13

Manifold - muffler diaphragm tightening clamp 16 to 18

LUBRICATION

Name

Torque in Nm

Hub oil drainage plug 15 to 17

Oil filter on crankcase fitting 27 ÷ 33

Engine oil drainage plug/ mesh filter 24 ÷ 30

Oil filter 4 ÷ 6

Oil pump cover screws 7 ÷ 9

Screws fixing oil pump to the crankcase 5 ÷ 6

Oil pump command crown screw 10 ÷ 14

Oil pump cover plate screws 4 ÷ 6

Oil sump screws 10 ÷ 14

Minimum oil pressure sensor 12 ÷ 14

CYLINDER HEAD

Name

Torque in Nm

Spark plug 12 to 14

Head cover screws 6 ÷ 7

Nuts fixing head to cylinder 7±1 + 10±1 + 270°

Head fixing side screws 11 ÷ 12

Starter ground screw 7 ÷ 8.5

Tappet adjustment check nut 6 ÷ 8

Intake manifold screws 11 to 13

Timing chain tensioner slider screw 10 ÷ 14 Start up counterweight support screw 11 to 15 Timing chain tensioner support screw 11 ÷ 13

Timing chain tensioner central screw 5 ÷ 6

Camshaft retention plate screw 4 ÷ 6

TRANSMISSION

Name

Torque in Nm

Belt support roller screw 11 ÷ 13

Clutch unit nut on driven pulley 45 to 50

Characteristics Vespa GTS Super 125 i.e. (2009)

CHAR - 16

Name Torque in Nm

Drive pulley nut 75 ÷ 83

Transmission cover screws 11 ÷ 13

Driven pulley shaft nut 54 ÷ 60

Rear hub cap screws 24 ÷ 27

FLYWHEEL

Name Torque in Nm

Flywheel cover screw 11 ÷ 13

Stator assembly screws 3 ÷ 4 (Apply LOCTITE 242 medium-strength threadlock)

Flywheel nut 94 ÷ 102

Pick-up fixing screws 3 ÷ 4

Screw fixing freewheel to flywheel 13 ÷ 15

CRANKCASE AND CRANKSHAFT

Name Torque in Nm

Internal engine crankcase bulkhead (transmission-side half

shaft) screws

4 ÷ 6

Engine-crankcase coupling screws 11 ÷ 13

Starter screws 11 ÷ 13

Crankcase timing cover screws 3.5 ÷ 4.5 (Apply LOCTITE 242 medium-strength threadlock)

COOLING

Name Torque in Nm

Water pump rotor cover 3 to 4

Thermostat cover screws 3 to 4

Bleed screw 3

Overhaul data

Assembly clearances

Cylinder - piston assy.

- Calculate the coupling clearance between pin and connecting rod end.

Characteristic

Standard diameter:

Ø 14.996 ÷ 15.0 mm

Standard clearance:

0.015 ÷ 0.029 mm

Vespa GTS Super 125 i.e. (2009) Characteristics

CHAR - 17

- Measure the diameter of the bearings on the piston.

Characteristic

Standard diameter:

15 +0.006 + 0.001mm

- Calculate the piston pin coupling clearance.

N.B.

THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS. FOR THIS REASON, MEASUREMENT MUST BE MADE ACCORDING TO THE PISTON AXIS.

Characteristic

Standard clearance:

0.001 ÷ 0.010 mm

- Check that coating is free from flakes.

- Check that the head matching surface exhibits no deformations or wear.

Characteristic

Maximum allowable run-out:

0.05 mm

- Pistons and cylinders are classified into categories based on their diameter. The coupling is carried out in pairs (A-A, B-B, C-C, D-D).

Characteristics Vespa GTS Super 125 i.e. (2009)

CHAR - 18

*Fit rings «2» and «3» with the word «TOP» facing upwards. ** Position the port of the rings as shown here. *** Value «A» of the sealing ring inside the cylinder (fitting clearance).

Check the size of the sealing ring opening: Compression ring 0.15 ÷ 0.30 mm. Max. value 0.5 mm Oil scraper ring 0.10 ÷ 0.30 mm. Max. value 0.65 mm Oil scraper ring 0.15 ÷ 0.35 mm. Max. value 0.65 mm

N.B.

FITTING CLEARANCE VALUES ARE THE SAME FOR BOTH THE STANDARD SEALING RINGS AND THE OVERSIZES.

Vespa GTS Super 125 i.e. (2009) Characteristics

CHAR - 19

ENGINE COUPLING CATEGORIES

Name

Initials Cylinder Piston Play on fitting

Cylinder A 56.997 to 57.004 56.945 ÷ 56.952 0.045 - 0.059 Cylinder B 57.004 to 57.011 56.952 ÷ 56.959 0.045 - 0.059

Piston C 57.011 to 57.018 56.959 ÷ 56.966 0.045 - 0.059

Piston D 57.018 to 57.025 56.966 ÷ 56.973 0.045 - 0.059 Cylinder 1st Oversize A1 57.197 to 57.204 57.145 ÷ 57.152 0.045 - 0.059 Cylinder 1st Oversize B 1 57.204 to 57.211 57.152 ÷ 57.159 0.045 - 0.059

Piston 1st Oversize C 1 57.211 to 57.218 57.159 ÷ 57.166 0.045 - 0.059

Piston 1st Oversize D 1 57.218 to 57.225 57.166 ÷ 57.173 0.045 - 0.059 Cylinder 2nd Oversize A2 57.397 to 57.404 57.345 ÷ 57.352 0.045 - 0.059 Cylinder 2nd Oversize B 2 57.404 to 57.411 57.352 ÷ 57.359 0.045 - 0.059

Piston 2nd Oversize C 2 57.411 to 57.418 57.359 ÷ 57.366 0.045 - 0.059

Piston 2nd Oversize D 2 57.418 to 57.425 57.366 ÷ 57.373 0.045 - 0.059 Cylinder 3rd Oversize A 3 57.597 to 57.604 57.545 ÷ 57.552 0.045 - 0.059 Cylinder 3rd Oversize B 3 57.604 to 57.611 57.552 ÷ 57.559 0.045 - 0.059

Piston 3rd Oversize C 3 57.611 to 57.618 57.559 ÷ 57.566 0.045 - 0.059 Piston 3rd Oversize D 3 57.618 to 57.625 57.566 ÷ 57.573 0.045 - 0.059

N.B.

THE PISTON MUST BE INSTALLED WITH THE ARROW FACING TOWARDS THE EXHAUST SIDE, THE PISTON RINGS MUST BE INSTALLED WITH THE WORD «TOP» OR THE STAMPED MARK FACING UPWARDS.

Characteristics Vespa GTS Super 125 i.e. (2009)

CHAR - 20

Crankcase - crankshaft - connecting rod

- Measure the diameter of bushings «A» in the three directions shown in the figure.

- Measure the diameter of the crankshaft bearings «B».

- Check that the diametral clearance «A-B» is be- tween the pre-set interval.

Characteristic

Diameter clearance

0.023 ÷ 0.041 mm

If value «A-B» is above the limit, check that value «B» is within the admissible values of the categories.

CRANKSHAFT

Specification

Desc./Quantity

Category 1 28.998 to 29.004 Category 2 29.004 to 29.010

If the crankshaft is within the set limits, replace the crankshaft half-bearings mounting the crankcase so as to suit the specified couplings. The crankcase halves can be mounted with four types of crankshaft half-bearings identified by letters- B (blue), C (yellow), E (green).

CRANKCASE

Specification

Desc./Quantity

Category 1 32.959 ÷ 35.965 Category 2 32.953 to 32.959

CRANKCASE - CRANKSHAFT COUPLING / CRANKSHAFT HALF-BEARINGS

Specification

Desc./Quantity

Crankshaft category 1 - Crankcase category 1 E+E Crankshaft category 2 - Crankcase category 1 C+C Crankshaft category 1 - Crankcase category 2 C+C Crankshaft category 2 - Crankcase category 2 B+B

Vespa GTS Super 125 i.e. (2009) Characteristics

CHAR - 21

Characteristic

Axial crankshaft/crankcase clearance:

0.5 ÷ 0.40 mm

CRANKSHAFT/ CRANKCASE AXIAL CLEARANCE

Name

Description Dimensions Initials Quantity

Transmissionside half-

shaft

16.6 +0-0.05 A D = 0.20 to 0.50

Flywheel-side halfshaft 16.6 +0-0.05 B D = 0.20 to 0.50

Connecting rod 18 -0.10 -0.15 C D = 0.20 to 0.50

Spacer tool 51.4 +0.05 E D = 0.20 to 0.50

Characteristics Vespa GTS Super 125 i.e. (2009)

CHAR - 22

THE CRANKSHAFT is available in two CATEGORIES:

Characteristic

Crankshaft category: CAT. 1 - CAT. 2

CRANKSHAFT CATEGORY IDENTIFICATION:

The identification is indicated on the counterweight shoulder «*1 - *2», if carried out with micropinholing. Otherwise, «1 - 2» if done manually with an electric pen. The spare part identification is located on the package with a drawing number plus FC1/FC2 or (001/002). If a crankshaft comprising two half-shafts of different categories needs to be replaced, also replace both crankcase halves, combining the two components (Shaft and Crankcase) featuring the same category.

Cylinder Head

Before performing head service operations, thoroughly clean all coupling surfaces. Note the position of the springs and the valves so as not to change the original position during refitting

- Using a trued bar and a feeler thickness gauge check that the cylinder head surface is not worn or distorted.

Characteristic

Maximum allowable run-out

0.09 mm

- In case of irregularities, replace the head.

- Check the sealing surfaces for the intake and exhaust manifold.

- Check that the camshaft and the rocking lever pin capacities exhibit no wear.

- Check that the head cover surface is not worn.

- Check that the coolant sealing pad exhibits no oxidation.

Vespa GTS Super 125 i.e. (2009) Characteristics

CHAR - 23

- Insert the valves into the cylinder head.

- Alternatively check the intake and exhaust valves.

- The test is carried out by filling the manifold with petrol and checking that the head does not ooze through the valves when these are just pressed with the fingers.

Measure the camshaft bearing seats and rocking lever support pins with a bore meter

HEAD BEARINGS

Specification

Desc./Quantity

Bearing "A" 37 +0.025 Bearing "B" 20 +0.021

Bearing "C" 12 +0.018

- Measure the unloaded spring length.

Characteristic

Standard length

40.5 mm

Allowable limit after use:

39.7 mm

- Clean the valve seats of any carbon residues.

- Using the Prussian blue, check the width of the impression on the valve seat "V".

Characteristic

Admissible limit:

1.6 mm

- If the width of the impression on the valve seat exceeds the specified limits, replace the cylinder head.

Characteristics Vespa GTS Super 125 i.e. (2009)

CHAR - 24

- In case of excessive wear or damage, replace the head.

STANDARD VALVE LENGTH

Specification Desc./Quantity

Intake 84.5 mm

Exhaust 94.5 mm

- Measure the diameter of the valve stems in the three positions indicated in the diagram.

STANDARD DIAMETER

Specification

Desc./Quantity

Intake: 4.987 - 4.972 mm

Exhaust: 4.975 - 4.960 mm

MINIMUM ADMISSIBLE DIAMETER

Specification

Desc./Quantity

Intake: 4.96 mm

Exhaust: 4.945 mm

- Calculate the clearance between valve and valve guide.

- Check the deviation of the valve stem by resting it on a «V» shaped abutment and measuring the extent of the deformation with a dial gauge.

Characteristic

Limit values admitted:

0.1 mm

Vespa GTS Super 125 i.e. (2009) Characteristics

CHAR - 25

- Check the concentricity of the valve head by arranging a dial gauge at right angle relative to the valve head and rotate it on a "V" shaped abutment.

Characteristic

Admissible limit:

0.03 mm

Measure the valve guide.

Characteristic

Valve guide:

5 +0.012 mm

- After measuring the valve guide diameter and the valve stem diameter, check clearance between guide and stem.

EXHAUST

Specification

Desc./Quantity

Standard clearance: 0.025 to 0.052 mm

Admissible limit: 0.09 mm

INTAKE

Specification

Desc./Quantity

Standard clearance: 0.013 - 0.04 mm

Admissible limit: 0.08 mm

- Check that there are no signs of wear on the surface of contact with the articulated register terminal.

Characteristics Vespa GTS Super 125 i.e. (2009)

CHAR - 26

- If no anomalies are found during the above checks, you can use the same valves. To obtain better sealing performance, grind the valve seats. Grind the valves gently with a fine-grained lapping compound. During the grinding, keep the cylinder head with the valve axes in a horizontal position. This will prevent the lapping compound residues from penetrating between the valve stem and the guide (see figure).

CAUTION

TO AVOID SCORING THE FAYING SURFACE, DO NOT KEEP ROTATING THE VALVE WHEN NO LAPPING COMPOUND IS LEFT. CAREFULLY WASH THE CYLINDER HEAD AND THE VALVES WITH A SUITABLE PRODUCT FOR THE TYPE OF LAPPING COMPOUND BEING USED.

CAUTION

DO NOT REVERSE THE FITTING POSITIONS OF THE VALVES (RIGHT - LEFT).

- Check that the camshaft bearings exhibit no scores or abnormal wear.

- Using a micrometer, measure the camshaft bearings.

STANDARD DIAMETER

Specification

Desc./Quantity

Bearing A Ø: 37 - 0.025 -0.050 mm

Bearing B diameter: 19 - 0.020 -0.041 mm

MINIMUM ADMISSIBLE DIAMETER

Specification

Desc./Quantity

Bearing A Ø: 36.940 mm

Bearing B diameter: 19.950 mm

Vespa GTS Super 125 i.e. (2009) Characteristics

CHAR - 27

-Using a gauge, measure the cam height.

STANDARD HEIGHT

Specification Desc./Quantity

intake 17.382 mm

Exhaust 16.563 mm

ADMISSIBLE LIMITS

Specification Desc./Quantity

intake 17.130 mm

Exhaust 16.310 mm

standard axial clearance 0.11 - 0.41 mm

maximum admissible axial clearance 0.42 mm

- Check that the rocking lever pins exhibit no scores or wear.

Characteristic

Standard diameter

Diameter 11.977 - 11.985 mm

- Measure the inside diameter of each rocking lever.

Characteristic

Standard diameter

Ø 12 +0.011 mm

Characteristics Vespa GTS Super 125 i.e. (2009)

CHAR - 28

- Check that the cam contact sliding block and the articulated register plate is free from wear.

- In case of wear, replace the component.

Slot packing system

Characteristic

Compression ratio

Cr: 11.50 ÷ 13:1

Measurement «A» to be taken, is a value of piston protrusion. It indicates by how much the plane formed by the piston crown protrudes from the plane formed by the upper part of the cylinder. The further the piston protrudes from the cylinder, the thicker the base gasket to be used (to restore the compression ratio) and vice versa.

N.B.

NO GASKETS AND SEALS SHOULD BE ASSEMBLED BETWEEN THE CRANKCASE AND CYLINDER AND THE DIAL GAUGE EQUIPPED WITH SUPPORT SHOULD BE SET TO ZERO FOR MEASUREMENT «A» TO BE TAKEN WITH THE PISTON AT TOP DEAD CENTRE POSITION AND ON A RECTIFIED PLANE.

Vespa GTS Super 125 i.e. (2009) Characteristics

CHAR - 29

MODELS WITH METAL HEAD GASKET (0.3)

Name Measure A Thickness

Shimming 125 - Cylinder 67.8 - Head

gasket 0.3 - Base gasket 0.6

1.40 ÷ 1.60 0.60 ± 0.05

Shimming 125 - Cylinder 67.8 - Head

gasket 0.3 - Base gasket 0.8

1.60 ÷ 1.80 0.80 ± 0.05

Products

VESPA GTS Super 125 i.e. (2009) Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual